Method of producing nonrun hosiery



Nov. 5, 1968 M. M. FREDERICK ET AL 3,408,833

METHOD OF PRODUCNG NONRUN HOSIERY 2 Sheets-Sheet l Filed Sept. 28, 1965 du ...wf 7

.3130 sms lNvEN'roRs; MAHLON M. Fszebamcm ROBERT I.. CoNNofes BYMMJ%,QM4V#A ATTORNEYS NOV 5, 1968 M. M, FREDERICK ET AL METHOD OF PRODUCING NONRUN HOSIERY 2 Sheets-Sheet 2 Filed Sept. 2S, 1965 .4.4 2 66%,45 M5 MSSMSMS INVENToRs: MAHLON M. FREBERICK ROBERT L.. CoNNoRs BYW/JQQL/ml.

ATTORNEYS nited States 3,408,833 METHOD F PRODUCING NONRUN HOSIERY Mahlon M. Frederick, Souderton, Pa., and Robert L. Connors, Saratoga Springs, N.Y., assignors to VaclHosiery Corporation, Charlotte, N.C., a corporation of North Carolina Filed Sept. 28, 1965, Ser. No. 490,8354

7 Claims. (Cl. 66-'178) I I ABSTRACT 0F THE p DISCLOSURE This invention relates to a method of producingsheer ladies nonrun hosiery having the appearance of a plain, nonmesh, knit fabric in the leg and foot portions and wherein a special tuck-float stitch pattern is utilized to prevent runs in both upward and downward directions.

The present inventoon is an improvement in the method of producing sheer ladies nonrun seamless hosiery of the' type disclosed in the prior Frederick application Ser. No. 204,240, filed June 21, 1962, now Patent No. 3,212,299; Marlette et al. application Ser. No. 192,925, filed May 7, 1962, now Patent No. 3,212,298; and Matthews et al. application Ser. No. 180,289, filed Mar. 16, 1962, now Patent No. 3,212,297. Generally, the special tuck-float stitch patterns disclosed in these applications are formed byV knitting each successive course in the leg and foot portions with first and second yarns while alternately knitting and tucking the first yarn and alternately knitting and floating the second yarn to form the fabric entirely of tuck stitches ,with floats therebehind and without any, plain stitches separating they tuck stitches in either walewise or coursewise directions. The alternate wales in which the yarns tuck and float may be staggered after the knitting of each course or after the knitting of a pair of successive courses. In knitting the fabric with this special tuck-float stitch pattern, a greater length of the tucking yarn is ordinarily incorporated in the fabric and tends toxform loose, randomly disposed loops intertwined and dispersed between the loops of the floating yarn.

While this special tuck-float stitch pattern produces a hose having a sheer appearance and the fabric will not run in either direction, the loose loops of the tucking yarn tend to stand out from the fabric so that they may be easily picked and pulled. After the hose has been worn and washed several times, the number of pulled loose loops may increase to the point that the hose takes on a hairy leg appearance and the pulled loose yarn loops may roll up and produce pilling on the surface.

With the foregoing in mind, it is a main object of the present invention to provide a method of producing sheer ladies` nonrun hosiery having special tuck-float stitch patterns of the type described and wherein the size of the loose loops of the tucking yarn is substantially reduced so that the hosiery `maintains its sheer appearance and the pilling tendency is reduced or completely eliminated.

It is a more specific object ofthe present invention to provide a method of producing sheer hosiery of the type described wherein the first and second yarns utilized in each course have different degrees of shrinkage capacity and wherein the yarn having the greater shrinkage capacity is alternately knitted and tuckedwhile the yarn having the lesser shrinkage capacity is alternately knitted and floated. After completion of the knitting of` the hosiery, thevrst (knitting and tucking) .yarn `is shrunk to substantially reduce the size of the loose loops originally formed in the fabric by the knitting ,and tucking yarn. l

Some of the objects of the invention havingnbeen stated, other objects will appear as the description proceeds, when taken in connectionV with the accompanying ldraw.- ings, in which: y

FIGURE 1 is a sideelevation of a nonrun rhose-,made in accordance with therpresent invention andillustrating itsappearance after it is removed'frorn the v.knitting Amachine;

.FIGURE 2 is an enlarged fragmentary. view of asrnall fragment of the fabric enclosed within the dotted rectangle indicated at 2 in FIGURE 1 and schematically showing the manner in which the tucking yarn forms vlooserandornly disposed loops intertwinedA and dispersed between the stitch -loops of the.floating yarn, the fabric being is stretched condition;

FIGURE 3 is a view similar to FIGURE 2 but being taken in the area enclosed within the dotted rectangle 3 in FIGURE 1;

FIGURE 4 is a side elevation of the 'nonrun hoseafter it has been closed at the toe and boarded to set the shape therein;

FIGURE 5 is a view similar to FIGURE 2, being taken in the area enclosed within the dotted rectangle 5 in FIGURE 4 and diagrammatically lillustrating the re duction in size of the loose loops of the tucking yarn after this yarn is shrunk; and

FIGURE 6 is a view similar to FIGURE 3, being taken in the area enclosed by the dotted rectangle 6y in FIGURE 4.

The nonrun sheer hosiery fabric disclosed in the present application is preferably formed on a circular hosiery knitting machine with two yarns in each course. In one course of the fafbric shown in this application, one yarn alternately knits and tucks While the other yarn alternately knits and floats so that special tuck-float stitches are formed in every other Wale while held loops are formed of both yarns in the remaining wales. Then in the next course the tucks and floats are formed in the wales in which double yarn held loops were formed in the preceding course while the double yarn held loops are formed in the wales in which the tucks and floats were formed in the preceding course.l Thus, the tuck stitches are staggered walewise after eachcourse in a 1 X 1 pattern, as described in detail in said copending application Ser. No. 192,925, now Patent No. 3,212,298. However, it is to be understood that the pattern of al` ternating tuck stitches may be knit in the samewales for two courses before they are staggered in the next two courses, as described in detail in my copending application Ser. No. 204,240, now Patent No. 3,212,299.

As shown in FIGURE l, the greige hose H includes a turned welt 10, a shadow Welt 11, a leg portion 12, and a foot that has a heel pocket 13, a medial portion 14 and a toe pocket 15. The nonrun fabric is preferably knit in the circular courses of the leg 12 and medial portion 14 of the foot while the turned welt 10, shadow welt 11, heel and toe pockets 13, 15 may be formed in any suitable and conventional manner.

Referring particularly to FIGURE 3, it will be noted that each of the needle wales W-1 through W-5 consist of interconnected tuck-float or tuck stitches broadly indicated at T. In the fabric shown in FIGURE 2, modified tuck stitches broadly indicated at X are interspersed in a random pattern with the tuck stitches T. In both cases the successive tuck-stitches T and modified tuck nstitches"X"ineach"wale ar'edirectl'y connected together and there are no plain Istitches positioned |between them in either walewise or coursewise directions. Also, both the regular tuck stitches T and the modified tuck stitches X have a single yarn float F extending therebehin'd.

i Each course ofthe fabric is formed of a main or first tucking yarn M anda second or floating yarn S. In FIG- URES 2, 3, and 6, the tucking yarn M has -been speckled to help distinguish it from the oating yarn S. Also, in each of these'fabric drawings, the first or fioating yarn S and the second or tucking yarn M are each provided with numerical suffixes to aid in identifying the courses in which these yarns are knit. Both yarns are preferably fine denier (7 to l5) synthetic thermoplastic yarns, such as nylon and the tucking yarn M- has a greater shrinkage capacity than the floating yarn S. Y

Each of the tuck stitches T includes a double yarn held loop 20 formed of both yarns M and S, a single yarn tuck loop 21l formed of yarn M, and a iioat F fonmed of yarn S. Each of the modified tuck stitches X includes a single yarn held loopl 22 formed of the yarn S and a pair of interknit plain loops 23, 23a that are each formed of yarn M. The stitch structure is clearer and easier to identify in the fabrics shown in FIGURES 5 and 6 Where prime notations are added to the reference characters and in which fabrics the tucking yarn M has been shrunk to reduce the size of the loose loops. v

During the knitting of this type of nonrun fabric, all needles pick up and draw the tucking yarn M to stitch forming level in each course while only alternate needles pick up and draw the floating yarn S so that substantially twice the length of the tucking yarn M is incorporated in the fabric. This excess length of the tucking yarn M in the fabric forms the loose randomly disposed loops in the fabric. This excess length of the main yarn M also causes the random formation of the modified tuck stitches X. The modified tuck stitch is -formed because the held loop of the tucking yarn M is looser than the held loop of the lioating yarn S so that it sometimes gets outside of or below the latch before the next tucking yarn is picked up. When this happens, the loose held yarn is in a position to be cast off the needle when the needle is lowered and forms the pair of stitches 23, 23a while the tight loop 22 is held.

While the regularity with which these modified tuck stitches are formed cannot be predicted, it has been found that a greater number of the modified tuck stitches are for-med While larger stitch loops are being formed in the upper leg portion of the hose and a lesser number of modified tuck stitches are formed while stitch loops of smaller size are being formed in the ankle. The drawings of the fabric (FIGURES 2, 3, 5 and 6) are not intended to indicate the relative numbers of tuck stitches T and modified tuck stitches X. In the actual hosiery fabric modified tuck stitches X may be found in the ankle portion as well as in the upper leg portion and in most cases there are more modified tuck stitches formed than regular tuck stitches.

When the loose loops of the tucking yarn M remain in the hose after finishing, they extend outwardly from the fabric where they are easily picked and pulled rby the clothing so that they present an undesirable hairy leg or pilling appearance. In accordance with the present invention, the size of the loose loops is substantially reduced by shrinking the tucking yarn M, as is schematically illustrated by comparing FIGURES 2 and 3 with FIG- URES 5 and 6. This reduction in size of the loose loops of the tucking yarn M also results in a clearer or sheerer appearance in the hosiery fabric. For economical reasons, it is preferred that the tucking yarn M be of a type that is shrinkable in response to heat so that the shrinkage may take place during the preboarding of the stocking.

It has been found that a satisfactory sheer nonrun hose may be knit in accordance with the following specific but nonlimiting example. A 10` denier monofilament type 66 Du Pont nylon yarn (normally having from 11% to 12% shrinkage capacity) is subjected to a steam treatment to shrink it about 7%, leaving about 4% to 5% shrinkage capacity in the yarn. This preshrunk yarn is then knit as the floating yarn S in each course of the nonrun hosiery fabric. A l0 denier monofilament type 6 Enka nylon yarn (having a shrinkage capacity of about 13% to 14%) is knit without any preshrinking as the tucking yarn M in each course. As these two yarns are knit together in each course of the nonrun fabric in the leg and foot portions 12, 14, the tucking yarn'M forms loose loops in the manner shown in FIGURES 2 and 3 while the lioating yarn S forms a relatively tight and regular pattern of alternating held loops and fioats.

The open toe end of the greige hose H (FIGURE l) is then closed by looping or sewing and placed on a preboarding form and subjected to steam under pressure. The hose is boarded at 260 F. for from 45 seconds to one minute with about 20 pounds of pressure so that the yarns are shrunk and set. During this boarding operation the floating yarn S shrinks a small amount (having about 4% to 5% shrinkage capacity) while the tucking yarn M shrinks a much greater amount (having about 13% to 14% shrinkage capacity) so that the loose randomly disposed loops of the tucking yarn M are greatly reduced in size, in the manner schematically illustrated in FIGURES 5 and 6. When the hose H (FIGURE 4) is removed from the boarding form, it has the desired shape set therein, there being enough remaining residual shrinkage in the oat yarn S to cause the hose to be drawn in against the boarding form. Since both of the yarns M and S are thermoplastic, the shape of the hosiery boarding form is set in the hose H (FIGURE 4).

As is well known, the amount of tension placed on a yarn during knitting also controls, to some degree, the amount of yarn that is incorporated in the stitch loops of a fabric. Therefore, the amount of tension placed on the tucking yarn M during the knitting operation may be varied as necessary so that the subsequent shrinkage of this yarn will reduce the size of the loose loops to the desired degree. Also, it may be desirable to positively feed or meter the tucking yarn M or the floating yarn S to control the length of either yarn incorporated in each course.

Since nylon yarn has a tendency to return to its original state upon being heated, the size of the loose loops in the present type of nonrun hosiery can be further reduced by stretching or drawing the tucking yarn M before it is knit. Thus, the total amount of shrinkage of the yam may be increased by first stretching a yarn having a high amount of residual shrinkage, knitting this yarn as the tucking yarn while knitting a yarn with a lesser amount of residual shrinkage as the floating yarn, and then heating the knit fabric to shrink the yarns. In this case, the tucking yarn will first be shrunk as it returns to its original length before stretching and it will be further shrunk as the residual shrinkage is removed so that the loose tucking yarn loops will be substantially reduced.

It is to be understood that this invention is not limited to the particular yarns described as other types of yarn having greater or lesser amounts of residual shrinkage may be utilized. Also, this invention is not limited to the boarding temperatures, times, pressures, etc., given in the particular example described. While the yarns described are shrinkable in response to the application of heat, other types of yarn could be utilized that are shrinkable in response to the application of chemicals or other substances. It is not essential that the shrinking of the tucking yarn take place during the boarding operation as it could take place prior to boarding if desired. Also, more than one boarding or shrinking operation can be used if desired.

In the drawings and specification there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

We claim:

1. A method of forming a nonrun knitted ladies sheer hose having the appearance of a plain, nonmesh, knit fabric, said method comprising the steps of:

(1) knitting complete courses in the leg portion with first and second yarns in each course, the first yarn having a greater shrinkage capacity than the second yarn, while alternately knitting and tucking the first yarn, and while alternately knitting and floating the second yarn and incorporating a greater length of the first yarn in the fabric, the excess length of the first yarn forming loose randomly disposed loops intertwined and dispersed between the loops of the second yarn, and

(2) shrinking at least the first yarn to substantially reduce the size of the loose loops formed therefrom.

2. A method of forming a nonrun knitted ladies sheer hose having the appearance of a plain, nonmesh, knit fabric, said method comprising the steps of:

(1) knitting complete courses in the leg portion with first and second shrinkable yarns in each course, the first yarn having a greater shrinkage capacity than the second yarn, while alternately knitting and tucking the first yarn, `and while alternately knitting and floating the second yarn and incorporating a greater length of the first yarn in the fabric, the excess length of the first yarn forming loose randomly disposed loops intertwined and dispersed between the loops of the second yarn, and

(2) shrinking both yarns while shrinking the first yarn to a greater extent than the second yarn to substantially reduce the size of the loose loops formed of the first yarn.

3. A method of forming a nonrun knitted ladies sheer hose having the appearance of a plain, nonmesh, knit fabric, said method comprising the steps of:

(1) knitting complete courses in the leg portion with first and second shrinkable yarns in each course, the first yarn having a greater shrinkage capacity than the second yarn, while alternately knitting and tucking the first yarn, and While alternately knitting and floating the second yarn and incorporating a greater length of the first yarn in the fabric, the excess length of the first yarn forming loose randomly disposed loops intertwined and dispersed between the loops of the second yarn, and

(2) treating the hose and shrinking both yarns while shrinking the first yarn to a greater extent than the second yarn to substantially reduce the size of the loose loops formed of the first yarn.

4. A method of forming a nonrun knitted ladies sheer hose having the appearance of a plain, nonmesh, knit fabric, said method comprising the steps of:

(1) preshrinking a synthetic yarn to remove at least a portion of the shrinkage capacity therefrom,

(2) knitting complete courses in the leg portion with the preshrunk yarn and a raw shrinkable synthetic yarn in each course while alternately knitting and tucking the raw yarn, and while alternately knitting and fioating the preshrunk yarn and incorporating a greater length of the raw yarn in the fabric, the excess length of the raw yarn forming loose randomly disposed loops intertwined and dispersed between the loops of the preshrunk yarn, and

(3) boarding the hose and shrinking the raw yarn to a greater extent than the preshrunk yarn to substantially reduce the size of the looser loops formed of the raw yarn.

5. In a method according to claim 4 wherein the yarns are each nylon, one of the yarns having about 11% to 12% shrinkage capacity and the other yarn having about 13% to 14% shrinkage capacity, and wherein about 7% of the shrinkage capacity of said one yarn is removed in the preshrinking step.

6. In a method according to claim 5 wherein the nylon yarns are each monolilament within the range of about 7 to 10 denier.

7. A method of forming a nonrun knitted ladies sheer hose having the appearance of a plain, nonmesh, knit o fabric, said method comprising the steps of:

(l) stretching `a first synthetic yarn having a relatively high amount of residual shrinkage,

(2) knitting complete courses in the leg portion with the first yarn and a second synthetic yarn in each course while alternately knitting and tucking the first yarn, and while alternately knitting and floating the second yarn and incorporating a greater length of the first yarn in the fabric, the excess length of the first yarn forming loose randomly disposed loops intertwined and dispersed between the loops of the second yarn, and (3) heating the hose and shrinking the first yam to a greater extent than the second yarn to substantially reduce the size of the loose loops of the first yarn.

References Cited UNITED STATES PATENTS 2,369,395 2/ 1945 Heymann 28-72 2,795,123 6/ 1957 Schumann 66-178 3,039,171 6/1962 Hume et al. 28-72 3,131,556 5/1964 Nebel 66-178 3,157,037 11/1964 Nebel et al 66-178 3,212,298 10/1965 Marlette et al. 66-178 3,287,938 11/1966 Knohl 66-178 2,994,214 8/ 1961 Wood, et al. 66--202 XR 3,085,410 3/1963 Loizillon 66-202 XR FOREIGN PATENTS 75,080 2/1961 France. 982,533 2/ 1965 Great Britain.

W. CARTER REYNOLDS, Primary Examiner. 

